Suzuki GS250 GSX250 400 450 TWINS Full Service & Repair Manual 1979-1985

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Typ: Motorcycle

Anbieter:

Art.-Nr: 148615

Stichworte: 1979 1980 1981 1982 1983 1984 1985 400 TWINS 450 TWINS GS Series GS250 GSX250 Motorcycle Motorcycles Suzuki

Produktvarianten

Beschreibung

This manual covers the GS250, GSX250, GS400, GS450, GSX400, and GSX450 TWINS models produced between 1979 and 1985. These versatile motorcycles, featuring parallel-twin engines ranging from approximately 231cc to 448cc, were known for their reliability and solid performance in the sport and touring segments of their era. The GSX variants often incorporated advanced technology such as DOHC heads and sportier styling, contributing to the growing reputation in the global motorcycle market. This comprehensive Factory Service Repair Workshop Manual provides detailed, step-by-step instructions for all aspects of maintenance, repair, and diagnostics. It covers engine overhaul, carburetor and ignition system service, transmission, clutch, chassis components, brakes, and electrical systems, including wiring diagrams. With hundreds of pages of detailed information, including critical torque specifications and clearances, this manual is an essential resource for owners, independent repair shops, and aspiring mechanics seeking to maintain and restore these classic motorcycles.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GS250/GSX250/400/450 TWINS

Model Code:

GS250, GSX250, GS400, GS450, GSX400, GSX450 (Specific sub-models may vary)

Generation

Production Years:

1979-1985

👋 Introduction

Market Position

Target Audience:

Suzuki motorcycle owners, independent repair shops, aspiring mechanics.

Competitive Analysis

Value Proposition:

Provides factory-level repair information for a range of popular Suzuki twin-cylinder motorcycles from the early 1980s, offering significant cost savings over dealership service.

Key Features

Content Quality:

Hundreds of pages with detailed photos and diagrams, step-by-step instructions, and exploded views.

Accessibility:

Instant download, usable on multiple devices, printable.

📋 Manual Details

Coverage Areas

Regions Covered:

Global (typically covers models sold in major markets)

Page Count

Estimated Pages:

Hundreds (as described, specific count not provided)

Manual Type

Type:

Factory Service Repair Workshop Manual

Description:

Comprehensive Factory Service Repair Workshop Manual designed for professional mechanics and technicians.

Language

Language:

English (implied by product description and typical manual content)

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, tuning, carburetor service, ignition system, cooling system (air-cooled), lubrication.

Transmission:

Clutch service, gear shifting mechanism, transmission overhaul, oil change.

Chassis:

Frame inspection, suspension (front forks, rear shock absorbers), steering system, wheel bearings.

Brakes:

Front and rear brake systems (disc and drum depending on model), hydraulic system, brake pad/shoe replacement.

Electrical:

Wiring diagrams, lighting system, charging system (alternator/stator, regulator/rectifier), starter motor, battery, ignition coils, fuses.

Fuel System:

Fuel tank, fuel lines, petcock, carburetor adjustment and rebuild (Mikuni/Keihin typical).

Bodywork:

Fairings, tank cover, seat removal, fenders, minor body panel repair.

Procedures Included

Maintenance:

Routine servicing, oil changes, filter replacements, spark plug replacement, chain adjustment, valve clearance checks.

Troubleshooting:

Diagnosis of common problems, symptom-based troubleshooting guides, electrical fault finding.

Repair:

Step-by-step instructions for component replacement and repair, including engine, transmission, and chassis components.

Diagnostics:

Detailed diagnostic procedures for all major systems, including electrical and mechanical faults.

Engine Rebuild:

Detailed steps for piston replacement, ring installation, bearing service, cylinder head removal and overhaul, crankshaft service.

Suspension Service:

Fork seal replacement, damper rod inspection, rear shock absorber inspection and replacement.

Technical Depth

Depth:

Comprehensive from basic maintenance to full engine and transmission rebuilds, suitable for professional mechanics.

Torque Specifications:

Includes critical torque values for engine, chassis, and brake components for correct assembly.

Clearances:

Valve clearances, ignition timing, and other critical component clearances specified.

📊 Manual Specifications

File Format

Format:

Searchable:

Likely searchable (typical for professional PDF manuals)

Print Quality

Printability:

Printable (single pages or entire manual)

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Compatibility

Operating Systems:

Windows & macOS

Licensing

Usage Rights:

Lifetime use, unlimited devices

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, four-stroke, parallel-twin (for GS250/400/450) and DOHC parallel-twin (for GSX250/400 models, and some 450 variations).

Displacement:

Approx. 231cc (GS250), 247cc (GSX250), 398cc (GS400/GSX400), 448cc (GS450/GSX450). Specific variations exist.

Performance

Horsepower:

Varies significantly by model and year, e.g., GS450L typically around 45-50 hp. GS250/GSX250 models lower.

Torque:

Varies by model and year, e.g., GS450L typically around 35-40 lb-ft.

Fuel System

Carburetors:

Typically dual Mikuni VM or constant velocity (CV) carburetors. Models like GSX often featured advanced multi-valve DOHC heads.

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition) with dual ignition coils for twin cylinders.

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh sequential gearbox.

Optional

Transmission Features:

Wet multi-plate clutch.

Features

Final Drive:

Chain drive.

📐 Dimensions

Exterior

Wheelbase:

Varies by model, typically around 55-58 inches (1400-1470 mm).

Weights

Dry Weight:

Varies by model, typically 330-380 lbs (150-170 kg).

🛡️ Safety Features

Ratings

Safety Standards:

Adheres to industry safety standards of the era. No formal crash test ratings as with modern cars.

Active Features

Braking System:

Front disc brake (often single caliper), rear drum brake typically. Some later models may have dual front discs or rear discs.

Passive Features

Lighting:

Headlight, taillight, brake light, turn signals.

💡 Technology Features

Infotainment

Features:

Basic analog instrumentation: speedometer, tachometer, odometer, trip meter, neutral indicator, high-beam indicator, oil pressure warning lamp, turn signal indicators.

Driver Assistance

Features:

None applicable (typical for motorcycles of this era).

Connectivity

Features:

None applicable.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-4,000 miles or 6 months, whichever comes first.

Valve Adjustment Interval:

Typically every 6,000-8,000 miles, or as specified in the manual.

Fluid Specifications

Engine Oil:

SAE 10W-40 or 20W-50 motorcycle-specific engine oil (API SE, SF, or SG classification recommended).

Brake Fluid:

DOT 3 or DOT 4 brake fluid (for hydraulic systems).

Transmission Oil:

Motorcycle-specific gear oil or engine oil meeting transmission lubrication requirements.

Known Issues

Carburetor Issues:

Gumming/clogging of carburetors due to fuel sitting, especially with ethanol fuels if not stored properly. Synchronization issues.

Electrical Issues:

Aging wiring harnesses, failing voltage regulators/rectifiers, corroded connectors, worn starter brushes.

Engine Wear:

Valve guide wear, potential cam chain wear over high mileage, oil leaks from gaskets and seals.

Common Repairs

Fork Seals:

Leaking front fork seals are a common maintenance item due to age and mileage.

📚 Vehicle History

Brand Heritage

Suzuki Motorcycles:

Suzuki has a long history in motorcycle manufacturing, known for innovation and performance across various displacement classes since the early 20th century.

Model Evolution

Twin Cylinder Lineup:

These models represented Suzuki's robust offering in the mid-size sport and touring segments. The GSX variants often featured more advanced technology like DOHC and sportier styling.

Production

Manufacturing Origin:

Japan

🏆 Awards & Recognition

Recognitions

Market Impact:

These models were well-regarded for their reliability, performance for their class, and good value, contributing to Suzuki's growing reputation in the 1980s motorcycle market.